US20050155689A1 - Method and device for producing gypsum plasterboards - Google Patents

Method and device for producing gypsum plasterboards Download PDF

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Publication number
US20050155689A1
US20050155689A1 US10/492,861 US49286104A US2005155689A1 US 20050155689 A1 US20050155689 A1 US 20050155689A1 US 49286104 A US49286104 A US 49286104A US 2005155689 A1 US2005155689 A1 US 2005155689A1
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US
United States
Prior art keywords
gypsum
suction
station
strip
paper
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/492,861
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English (en)
Inventor
Hans-Joachim Smolenski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Grenzebach BSH GmbH
Grenzebach GmbH and Co KG
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Assigned to BABCOCK-BSH GMBH reassignment BABCOCK-BSH GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALBERT, SABINE, SMOLENSKI, JANS-JOACHIM
Publication of US20050155689A1 publication Critical patent/US20050155689A1/en
Assigned to GRENZEBACH-BSH GMBH reassignment GRENZEBACH-BSH GMBH CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: BABCOCK-BSH GMBH
Assigned to GRENZEBACH BSH GMBH reassignment GRENZEBACH BSH GMBH CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: BABCOCK-BSH GMBH
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard

Definitions

  • the invention relates to a method of making gypsum board according to the introductory clause of claim 1 as well as to an apparatus for carrying out the method according to the introductory clause of claim 1 .
  • the boards For many uses of gypsum board it is desirable for the boards to be as light as possible. Thus at least a portion of the gypsum core has a network of pores that influence the density of the board.
  • the porosity has however the disadvantage that the bond at the interface between the gypsum core and the paper liner and thus the stability of the entire gypsum board are substantially weakened.
  • WO 95/32084 discloses a method of making gypsum boards wherein the bond between the gypsum core and the paper liners is supposed to be improved. A first layer and two edge strips of relatively dense gypsum are applied to a lower paper liner and a second layer of less dense gypsum is applied between the edge strips. The thus formed upper surface is smoothed and covered by the upper paper liner. After some curing there is further treatment including cutting and drying of the boards.
  • U.S. Pat. No. 2,949,505 describes a method wherein the paper liners are coated with a thin layer of plaster and then the board is produced in the normal manner.
  • the known methods and apparatuses have the disadvantage that they are expensive and associated with high costs and also produce an unsatisfactory bond between the gypsum core and the paper liners.
  • German 1,584,781 relates to a method of producing a gypsum board having ridges on one side by applying a gypsum slurry to a lower flat paper strip.
  • the gypsum slurry is shaped by a doctor blade into the ribs and is then covered with an upper ridge-shaped paper strip.
  • the gypsum slurry penetrates into the ridge-forming folds of the upper paper strip, they are braced by an outside subatmospheric pressure.
  • The thus produces a paper/gypsum/paper sandwich that is supported on a conveyor until the gypsum slurry cures and then is cut into sheets.
  • This method does not relate to the production of gypsum boards with porous cores.
  • the subatmospheric pressure is only applied at the ridges and thus is effective over only a small portion of the width of the system.
  • a further object is the production of an apparatus for carrying out the method.
  • the first object is attained by the characterizing clause of claim 1 .
  • the second object is attained by the characterizing features of claim 5 .
  • the apparatus makes it possible to carry out the method of the invention.
  • the selection of the level of the subatmospheric pressure in combination with its application time and the porosity of the paper according to claim 3 has the effect that on the one hand enough water is aspirated in order to achieve the desired effect and on the other hand tearing the paper from too much tension as a result of too great a subatmospheric pressure is avoided.
  • FIG. 1 is the region of the shaping station of an apparatus according to the invention for making gypsum boards with suction boxes seen from the side;
  • FIG. 2 schematically shows means for depressurizing a suction box
  • FIG. 3 is the region of the shaping station of another apparatus according to the invention with suction rollers seen from the side.
  • An apparatus according to the invention is comprised basically of two unwinding supplies, a shaping station, vacuum means with at least one suction device, a conveyor, at least one cutter, and a dryer.
  • FIGS. 1 and 3 only show the region of the shaping station with the suction device.
  • a lower paper strip 1 extends horizontally through the shaping station 3 and thence to the conveyor.
  • the shaping station 3 is comprised generally of a machine frame with an upper horizontal plate 4 over which the paper strip 1 is guided, with a mixer 5 , with means 6 for shaping a gypsum-board sandwich 7 and having suction boxes 8 and 9 forming the suction device.
  • the conveyor 2 seen in the transport direction 2 (shown by arrow 2 ) downstream of the shaping station 3 is formed with a transport device constituted for example as a conveyor belt 10 .
  • the mixer 5 is above the plate 4 and is connected to unillustrated feed lines for gypsum powder, water, and additives.
  • the lower side of the mixer 5 has openings connected to distributors 11 oriented above the paper strip 1 .
  • the shaping means 6 has two unillustrated lateral limiting bars that extend along the plate 4 up to the distributors 11 and that are parallel to each other and to the conveyor 2 of the paper strip 1 so as to establish the width of the gypsum-board sandwich 7 .
  • the shaping means 6 has a base plate 12 , a pressure plate 15 , and a hydraulic cylinder 16 .
  • the upper plane of the plate 4 is flush with the upstream end of the base plate 12 that then rises going downstream and finally ends parallel to the plate 4 .
  • An upper paper strip 13 is guided over deflecting rollers 14 such that it extends downstream of the upstream edge from the base plate 12 parallel to and at a spacing from the lower paper strip 1 .
  • the pressure plate 15 extends above and parallel to the upper paper strip 13 . It can be shifted vertically by the hydraulic cylinder 16 so that the spacing between the base plate 12 is and the pressure plate 15 corresponds exactly to the desired thickness of the gypsum-board sandwich 7 .
  • the suction boxes 8 and 9 are mounted between the shaping means 6 and the conveyor belt 10 .
  • the lower suction box 9 is oriented such that its upwardly directed suction face is coplanar with the lower surface of the lower paper strip 1 .
  • This plane is identical to the plane between the upper rear edge region of the base plate 12 and the upper surface of the conveyor belt 10 .
  • the upper suction box 8 is mounted such that its downwardly directed suction face is coplanar with the lower face of the pressure plate 15 .
  • the suction means is shown in FIG. 2 : It is comprised in this embodiment mainly of the suction box 9 , a pressure-maintaining valve 17 , a separator 18 , a suction pump 19 , as well as the associated conduits and gauges, this system being set up for each suction location.
  • the one longitudinal end of the suction box 9 is connected via the separator 18 with the suction pump 19 .
  • the other longitudinal end is connected with the pressure-maintaining valve 17 .
  • suction boxes 8 and 9 each with a respective separator 18 and a respective suction pump 19 .
  • FIG. 3 Another embodiment for the shaping station 3 is shown in FIG. 3 . It is generally the same as the embodiment of FIG. 1 , differing mainly in the shaping means 6 and suction means, the latter having suction rollers 20 and 21 .
  • the shaping means 6 has two unillustrated lateral limiting bars that extend along the plate 4 up to the distributors 11 and that are parallel to each other and to the conveyor 2 of the paper strip 1 so as to establish the width of the gypsum-board sandwich 7 , as well as an upper suction roller 21 .
  • the upper paper strip 13 is guided over deflecting rollers 14 to the upper suction roller 21 that is mounted rotatable about a horizontal axis perpendicular to the longitudinal axis of the lower paper strip 1 and that is vertically closely juxtaposed with the plate 4 .
  • the position of the axis is vertically adjustable.
  • the upper paper strip 13 is guided around the upper suction roller 21 and then extends parallel to and at a spacing above the lower paper strip 1 .
  • the shaping means includes a lower suction roller 20 set in a complementary opening of the plate 4 and rotatable such that it tangents the upper plane of the plate 4 and its axis is horizontal and perpendicular to the transport direction 2 , upstream of the upper suction roller 21 .
  • the lower paper strip 1 is continuously pulled from a roll and guided over the plate 4 through the shaping means 6 to the conveyor belt 10 .
  • the mixer 5 is supplied via lines with gypsum powder, water, foaming agent, and if necessary additives and forms a light gypsum slurry 22 . This is spread in a uniform layer by the distributors 11 over the width of the passing lower paper strip 1 .
  • the lateral limiting bars prevent the gypsum slurry 22 from flowing over the edges of the lower paper strip 1 .
  • the upper paper strip 13 is fed from a second roll in the standard manner to the shaping means 6 where its surface is pressed into the still wet gypsum slurry and is then formed with the lower paper strip 1 and the gypsum slurry 22 into the final shape of the gypsum-board sandwich 7 with respect to thickness, width, and if necessary any special shaping of the edges.
  • the edges of the lower paper strip 1 which is wider than the upper paper strip 13 , are folded up and overlapped thereover.
  • the suction devices here for example the suction boxes 8 and 9 or the suction rollers 20 and 21 , apply a subatmospheric pressure of e.g. ⁇ 0.2 bar ( ⁇ 0.8 bar(abs)) to the outer faces of the lower paper strip 1 and the upper paper strip 13 .
  • This has two effects: On the one hand bubbles are eliminated in the gypsum slurry inward of the paper strips 1 and 13 so that the density of the gypsum slurry immediately adjacent the paper strips 1 and 13 is higher than in the rest of the core. In particular the interface at the paper strips 1 and 13 has virtually no gaseous inclusions. On the other hand excess water in the gypsum is sucked out through the paper strips 1 and 13 .
  • the gypsum boards have a porosity that is greater at the center and decreases toward the paper liners.
  • a gypsum board that is 12.5 mm thick has a weight of 7.6 kg/m 2
  • the standard minimum weight is 9 kg/m 2 .
  • the subatmospheric pressure applied to the suction device is set in accordance for example with the type of paper and the production speed.
  • the shaped gypsum-board sandwich 7 is as known conveyed away so that the gypsum sets and hardens, and after setting it is cut into boards and loaded into the dryer.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Finishing Walls (AREA)
US10/492,861 2001-08-17 2002-08-09 Method and device for producing gypsum plasterboards Abandoned US20050155689A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE101394209 2001-08-17
DE10139420A DE10139420B4 (de) 2001-08-17 2001-08-17 Verfahren und Vorrichtung zum Herstellen von Gipskartonplatten
PCT/EP2002/008899 WO2003016010A1 (de) 2001-08-17 2002-08-09 Verfahren und vorrichtung zum herstellen von gipskartonplatten

Publications (1)

Publication Number Publication Date
US20050155689A1 true US20050155689A1 (en) 2005-07-21

Family

ID=7695089

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/492,861 Abandoned US20050155689A1 (en) 2001-08-17 2002-08-09 Method and device for producing gypsum plasterboards

Country Status (6)

Country Link
US (1) US20050155689A1 (de)
EP (1) EP1420926B1 (de)
AT (1) ATE332221T1 (de)
CA (1) CA2462520A1 (de)
DE (2) DE10139420B4 (de)
WO (1) WO2003016010A1 (de)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070110970A1 (en) * 2003-09-18 2007-05-17 Ashish Dubey Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels with enhanced fiber content
US20080101151A1 (en) * 2006-11-01 2008-05-01 United States Gypsum Company Apparatus and method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US20080101150A1 (en) * 2006-11-01 2008-05-01 United States Gypsum Company Method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US20090011212A1 (en) * 2003-09-18 2009-01-08 Ashish Dubey Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels
US7513768B2 (en) 2003-09-18 2009-04-07 United States Gypsum Company Embedment roll device
US7754052B2 (en) 2006-11-01 2010-07-13 United States Gypsum Company Process and apparatus for feeding cementitious slurry for fiber-reinforced structural cement panels
US8038915B2 (en) 2006-11-01 2011-10-18 United States Gypsum Company Panel smoothing process and apparatus for forming a smooth continuous surface on fiber-reinforced structural cement panels
CN115741948A (zh) * 2022-12-21 2023-03-07 井冈山北新建材有限公司 一种石膏板成型装置
US12338621B2 (en) 2021-09-17 2025-06-24 United States Gypsum Company Structural load-bearing wall

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2694283B1 (de) 2011-04-01 2017-03-22 Knauf Gips KG Karton mit optimierter gipskernhaftung

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1584781A (en) * 1925-04-11 1926-05-18 Langworthy Mitchell Portable fracture bed
US2940505A (en) * 1952-10-16 1960-06-14 British Plaster Board Ltd Production of plaster board
US3260635A (en) * 1963-08-22 1966-07-12 United States Gypsum Co Production of ribbed building board
US5718797A (en) * 1994-05-25 1998-02-17 National Gypsum Company Apparatus for manufacturing gypsum board
US6190476B1 (en) * 1998-07-08 2001-02-20 Westroc Inc. Gypsum board manufacture with co-rotating spreader roller

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6475313B1 (en) * 2000-09-20 2002-11-05 United States Gypsum Company Process for making gypsum board having improved through-penetration strength

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1584781A (en) * 1925-04-11 1926-05-18 Langworthy Mitchell Portable fracture bed
US2940505A (en) * 1952-10-16 1960-06-14 British Plaster Board Ltd Production of plaster board
US3260635A (en) * 1963-08-22 1966-07-12 United States Gypsum Co Production of ribbed building board
US5718797A (en) * 1994-05-25 1998-02-17 National Gypsum Company Apparatus for manufacturing gypsum board
US6190476B1 (en) * 1998-07-08 2001-02-20 Westroc Inc. Gypsum board manufacture with co-rotating spreader roller

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7789645B2 (en) 2003-09-18 2010-09-07 United States Gypsum Company Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels
US20090011212A1 (en) * 2003-09-18 2009-01-08 Ashish Dubey Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels
US7513768B2 (en) 2003-09-18 2009-04-07 United States Gypsum Company Embedment roll device
US7670520B2 (en) 2003-09-18 2010-03-02 United States Gypsum Company Multi-layer process for producing high strength fiber-reinforced structural cementitious panels with enhanced fiber content
US20070110970A1 (en) * 2003-09-18 2007-05-17 Ashish Dubey Multi-layer process and apparatus for producing high strength fiber-reinforced structural cementitious panels with enhanced fiber content
US20080101151A1 (en) * 2006-11-01 2008-05-01 United States Gypsum Company Apparatus and method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US20080101150A1 (en) * 2006-11-01 2008-05-01 United States Gypsum Company Method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US7513963B2 (en) * 2006-11-01 2009-04-07 United States Gypsum Company Method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US7524386B2 (en) 2006-11-01 2009-04-28 United States Gypsum Company Method for wet mixing cementitious slurry for fiber-reinforced structural cement panels
US7754052B2 (en) 2006-11-01 2010-07-13 United States Gypsum Company Process and apparatus for feeding cementitious slurry for fiber-reinforced structural cement panels
US8038915B2 (en) 2006-11-01 2011-10-18 United States Gypsum Company Panel smoothing process and apparatus for forming a smooth continuous surface on fiber-reinforced structural cement panels
US12338621B2 (en) 2021-09-17 2025-06-24 United States Gypsum Company Structural load-bearing wall
CN115741948A (zh) * 2022-12-21 2023-03-07 井冈山北新建材有限公司 一种石膏板成型装置

Also Published As

Publication number Publication date
WO2003016010A1 (de) 2003-02-27
DE10139420A1 (de) 2003-03-06
EP1420926A1 (de) 2004-05-26
CA2462520A1 (en) 2003-02-27
ATE332221T1 (de) 2006-07-15
EP1420926B1 (de) 2006-07-05
DE50207446D1 (de) 2006-08-17
DE10139420B4 (de) 2006-07-27

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Legal Events

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AS Assignment

Owner name: BABCOCK-BSH GMBH, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:SMOLENSKI, JANS-JOACHIM;ALBERT, SABINE;REEL/FRAME:015824/0911;SIGNING DATES FROM 20040325 TO 20040331

AS Assignment

Owner name: GRENZEBACH-BSH GMBH, GERMANY

Free format text: CHANGE OF NAME;ASSIGNOR:BABCOCK-BSH GMBH;REEL/FRAME:016649/0106

Effective date: 20030430

AS Assignment

Owner name: GRENZEBACH BSH GMBH, GERMANY

Free format text: CHANGE OF NAME;ASSIGNOR:BABCOCK-BSH GMBH;REEL/FRAME:017003/0642

Effective date: 20030403

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION